Shoe bottom unit and method of making the same



April 1943- T. c. MORRIS ETAL 2,317,475

SHOE BOTTOI UNITS AND METHOD OF MAKING THE SAME Filed Nov. 5, 1941 2Sheets-Sheet 1 April 1943- I T. c. MORRIS ETAL 2,317,475

SHOE BOTTOM UNITS AND METHOD OF MAKING THE SAME Filed Nov. 5, 1941 2Sheets-Sheet 2 Patented Apr. 27, 1943 SHOE BOTTOM UNIT AND METHOD OFMAKING THE SAME Thomas 0. Morris, Belmont, and Frank S. Gregory, Jr.,Burlington, Mass, assignors to United Shoe Machinery Corporation,Flemington, N. J a corporation of New Jersey Application November 5,1941, Serial No. 417,904

46 Claims.

This invention relates to improvements in shank pieces and bottom unitsfor use in shoes and to improved methods of making such members.

It has been the usual practice heretofore in. the manufacture of themore common types of shoes to reinforce the shank and heel portions ofthe insole in order to render these portions of the shoe bottom,particularly the shank portion, hard and stiff enough to hold theirshape under the weight of the body and thereby insure that the foot willbe properly supported during the wearing of the shoe. The reinforcing ofthe shank and heel portions of the shoe bottom has usually beenaccomplished by attaching a piece of relatively stiff fibrous material,such as flberboard or the like, to the shank and heel portions of theinsole and then introducing a r latively narrow shank stiffener betweenthe insole and reinforcing member, the shank stiffener being composed ofsteel and being shaped in accordance with the longitudinal curvature ofthe shank and heel portions of the shoe bottom. The shank stiffener isusually positioned centrally of the insole and extends from the heelseat portion to the ball line of the shoe. It is secured in position bytacks or staples or by prongs formed on the stiffener itself. Theassembled parts including the stiffener are then molded into conformitywith the longitudinal contour of the bottom of a last.

While shoes reinforced in this manner or by similar means are in generalsatisfactory and usually give good results, the use of a steel shankstiffener in the bottom of the shoe has some disadvantages among whichis the fact that the shank stiffener sometimes works loose or changesposition in the shoe bottom so that it forms a floating support, or itmight even break under the strains of constant and heavy pressure duringwear. Moreover, as the shoe is worn a steel shank stiffener often has atendency to work through the insole at the ball portion and thus show onthe inside of the shoe. Since the shank stiffener, aithough providingthe chief means of support at the shank and heel portions of the shoebottom. is quite narrow, the foot has practically no supporttransversely or widthwise and consequently it may tip laterally duringwalking which produces an uneven tread, thereby causing the shoe to loseits shape, particularly at its heel and back portions, and to wear outtoo quickly, this result, of course, being detrimental to the foot.Another disadvantage of a steel shank stiffener is that in shoes havingtheir outsoles sewed or nailed to the shoe bottom, the

shank stiffener may interfere with the sewing or nailing operation,particularly in shoes having extremely narrow shank portions.

Important objects of the present invention are to provide an improvedshank piece in which the above difiiculties are overcome or eliminated,to provide an improved shoe bottom unit embodying such a shank piece,and to provide improved methods of making the shank piece and shoebottom unit.

To these ends and in accordance with one of its aspects, the inventionprovides, as a new article of manufacture, an improved shank piece oflaminated formation consisting of a plurality of layers of fibrousmaterial impregnated with, and secured in assembled relation by,hardened stiffening material of an adhesive nature. As illus trated, thelayers of the shank piece comprise outer layers of relatively stiif,rigid material and inner layers of relatively flexible material.Preferably, and as herein illustrated, the outer layers are composed ofwood and the inner layers comprise layers of paper and layers of fabricmaterial, a layer of wood being also included, if desired, for addedstrength and rigidity. It will be noted, however, that although theouter layers of the shank piece are composed of fibrous material whichis normally stiffer and more rigid than the material of the innerlayers, these outer layers are nevertheless of a character offering lessresistance to penetration, for example, by lasting fastenings or thelike than the material of the inner layers.

The reinforcing or stiffening material with V which the layers areimpregnated is of an adhesive or bonding nature and is preferably alsothermoplastic in character so that the layers, after being impregnatedand stiffened thereby, can be rendered pliable again to permit them tobe secured together in assembled relation and to be molded into thedesired shape, or to permit the shank piece when completed to beremolded to a different or more accurate shape.

In order that the shank piece will support the foot transversely orwidthwise as well as longitudinally, the outer layers and preferablysome of the inner layers are shaped to correspond in outline to the edgecontour of the shank and heel portions of an insole, for example, theinsole with which the shank piece is to be used in a shoe. The rest ofthe inner layers are arranged to diminish graduallyin size from that ofsaid outer layers to much smaller layers, this reduction in size takingplace progressively from an upper inner layer to a lower inner layer. In

this way the shank piece is provided with a body portion which isthicker at its central portion than at its margins to provide maximumstrength without being too bulky for the space it should occupy in thenormal shoe bottom.

In addition to being coextensive with the shank and heel portions of aninsole, the illustrated shank piece conforms approximately in shape tothe longitudinal and transverse curvatures of the bottom of a last.Since the stiffening material with which the layers are impregnated isof a thermoplastic nature, the hardened materials of the shank piece canbe rendered pliable again under proper activation, such as heat andpressure, and can be remolded to conform the shank piece accurately tothe shape of the bottom of a particular last as, for example, the lastupon which the shoe is to be made. In this way the shank piece can bemade to fit the bottom of a particular last without the necessity ofproviding separate molds for each size and shape of last, which, ofcourse, would require so many molds that the expense would beprohibitive.

The illustrated invention also provides, as a new article ofmanufacture, animproved shoe bottom unit adapted for use in a shoewithout additional preparation or treatment, said unit consisting of thelaminated shank piece of fibrous material having the furthercharacteristics pointed out above, and an insole to which the shankpiece is secured to reinforce the shank and heel portions of the insoleand to form a complete unit. As herein illustrated, the fibrous shankpiece may be attached to the outer surface of the insole by an adhesivesuch as latex or rubber cement or, if desired, by a thermosettingadhesive, such as neoprene. The inner surface of the shoe bottom unitprovided by the insole is molded to render it substantially complementalin shape to the bottom of a particular last while the outer surface ofthe bottom unit, including the shank piece at the rear portion thereof,is caused to correspond generally in shape to the inner surface of theinsole except at the portion formed by the shank piece which has greatercurvature due to the materials making up the shank piece, that is, theinner layers forming the body portion of the shank piece. Since thehardened or stiffened material of the shank piece is capable of beingrendered pliable, the shank piece can be readily remolded into accurateconformity with the last bottom at the time the insole is moulded. Thecompleted shoe bottom unit, therefore, will have a firm, rigid shank andheel portion which is accurate in shape and is adapted to support thefoot transvers'eiy in the shoe as well as longitudinally, therebytending to produce a substantially even or uniform tread which reducesrun-over heels, broken breast flaps, and shoes having bulged ordistorted back parts or rear portions.

In its method aspects, the invention provides an improved method ofmaking bottom units for shoes which consists in providing a shank pieceof relatively stiff, rigid material which has been molded to conformapproximately-in shape to the bottom of a last, assembling this shankpiece with an insole on a last bottom, molding the insole into accurateconformity with the shape of the last bottom while simultaneouslyremolding the shank piece into accurate conformity with the shape of thelast bottom, and securing the insole and shank piece together to complate the shoe bottom unit. As illustrated, the shank piece is oflaminated formation and is composed of fibrous material, the layers ofthe shank piece having been impregnated with stiffening material of anadhesive nature which is also thermoplastic in character, therebypermitting the shank piece to be rendered pliable by activation of thestifiening material when it is desired to remold the shank piece informing the shoe bottom unit.

In still another aspect, the invention provides an improved method ofmaking shank pieces for shoes which consists in impregnating a pluralityof layers of fibrous material with stiffening material of an adhesivenature, cutting from the layers a plurality of members some of whichcorrespond in size and shape to the shank and heel portions of insoleand others of which diminish in size from the first-named members tomuch smaller members, assembling the members in superimposed relationwith the larger, insole-shaped members forming the outer layers of theassembly, and molding the assembled members under heat and pressure tosecure them in assembled relation and to fuse them together to form anintegral shank piece unit while simultaneously conforming the unit toapproximately the shape of the shank and heel portions of a last bottom.As illustrated, the outer or top and bottom layers of the shank pieceare composed of wood and the inner layers comprise layers of wood, paperand fabric material, respectively. The inner paper layers of the shankpiece are arranged so that they diminish progressively in size from anupper paper layer to a lower paper layer.

With the above and other objects and aspects in view, the invention willnow be described in connection with the accompanying drawings and willthereafter be pointed out in the claims.

In the drawings:

Fig. l is a perspective view of the members which form the shank piecearranged in assembled relation;

Fig. 2 is a longitudinal section taken on the line IIII of Fig. 1;

Fig. 3 is a sectional plan view, with portions broken away, taken on theline IIIIII of Fig. 2 as viewed from below;

Fig. 4 is a plan view simiiar to Fig. 3, taken on th line IV-IV of Fig.2 as viewed from above, with portions of the figure broken away;

Fig. 5 is a diagrammatic sectional View illustrating a method which maybe used to impregnate the materials of the shank piece;

Fig. 6 is a side elevation partly in section showing the members of theshank piece being molded to secure them together and to conform them toapproximately the shape of a last bottom;

Fig. 7 is a perspective view of the shank piece after it .has beenmolded, a portion of the shank piece being broken out to show its shapemore clearly;

Fig. 8 illustrates the operation of attaching the shank piece to aninsole and molding the insole and remolding the shank piece to the shapeof a last bottom;

Fig. 9 is a perspective view of the outer or lower side of the insoleand shank piece after they have been attached together and molded toform a single shoe bottom member or unit; and

Fig. 10 is a transverse section taken on the line X-X of Fig. 9.

The illustrated shank piece is of laminated formation and consists of aplurality of layers of fibrous material which, hereinafter explained.

are impregnated with a stiffening material of an adhesive or bondingnature to secure the layers together and to render them relatively stiffand rigid. After the layers of fibrous material have been impregnatedwith stiffening material, the members which are to form the shank pieceare out are died out of the layers and are arranged in assembledrelation, as illustrated in Figs. 1 to 4, inclusive.

Fibrous materials which may be used in making the shank piece comprise,as herein illustrated, relatively stiff, rigid material, such as wood,and relatively flexible materials such as fabric and paper. The woodmembers may be formed from wood veneer such, for example, as basswoodwhich is preferably about /2:; of an inch thick. The fabric material mayconsist of nine-ounce Gem duck while the paper is preferably unsizedkraft paper about .011 of an inch thick. As illustrated in Figs. 1 to 4,inclusive, the members or layers which form the shank piece are cut ordied out of these diflerent fibrous materials and are assembled in apredetermined relation to each other in order to be made into a singleunitary shank piece.

In accordance with the present method, the layers forming the shankpiece are preferably assembled in the following order: The lower orbottom layer 20 is composed of wood and, as illustrated in Figs. 1 to 4,corresponds in size and shape to the edge contour of the shank and heelportions of an insole which is preferably the one which is to be used inmaking the shoe. The top layer 22 of the shank piece is also composed ofwood and is shaped to correspond in outline to the shank and heelportions of the insole. These top and bottom or outer layers of thelaminated shank piece, therefore, are composed of material which isnormally relatively firm and stiff and which provides substantiallyrigid or non-yielding surfaces in the finished article for supportingthe foot. It should be pointed out, however, that although the woodwhich forms the material of the outer layers of the shank piece isnormally or in its natural condition more rigid and stifi than materialsuch as cloth or paper,

which is to form the inner layers, the wood is nevertheless of acharacter which offers less resistance to penetration by fasteningssuch, for example, as lasting tacks or staples or heel attaching nails,than the fabric and paper materials forming the inner layers,particularly when the latter materials are compressed or molded underrelatively heavy pressure.

Located above the bottom layer 20, as viewed in Figs. 1 to 4, is a layer24 of paper impregnated with stiffening material, as mentioned above,and corresponding in size and shape to the bottom layer 20. Above thepaper layer 24 is another layer 26 of wood which is also shaped like, oris coextensive with, the shank and heel portions of the insole so thatit coincides with the lower layers 20 and 24. Below the top layer 22 isa layer 28 of impregnated fabric material, such as the Gem duck referredto, which corresponds in size and shape with the top layer 22. Betweenthe fabric layer 28 and the-Wood layer 26 is interposed a plurality ofinner layers of the impregnated paper which, as illustrated in Figs. 2and 3, are smaller than the outer layers and diminish progressively insize from the top paper if layer to the lower paper layer.

As herein illustrated, there are preferably seven layers of paperbetween the wood layer 26 and the fabric layer 28, this number beingillustrative rather than an essential requirement, however, since thenumber may be increased or reduced if conditions seem to warrant. Theupper paper layer 30 corresponds substantially in shape to the fabriclayer 28 but is somewhat smaller, as shown in Figs. 2 and 3. Below thelayer 30 is another paper layer 32 similar to, but smaller than, thelayer 30 and below the layer 32 are three more paper layers 34, 36 and38, smaller than the layer 32 and tapering somewhat toward their forwardor right-hand end, as viewed in Fig. 3, the layers 34, 3B and 38 beingsubstantially equal in size and shape. Below the layer 38 are twosmaller paper layers 40, 42 substantially rectangular in shape and ofequalsize. As stated above, the paper is preferably unsized kraft paperwhich may be readily impregnated with stiffen- .ing material to renderit considerably stiffer and less flexible than it is normally.

In order to facilitate the assembling of the im-' pregnated layers ofthe shank piece in the manner just described, the upper fabric layer 28and the seven inner paper layers may be first assembled, as shown inFigs. 2 and 3, and secured in assembled relation by a single staple 44to form a unit, the staple being clinched against the upper fabric layer28. Also, if desired, the three lower layers 21], 24, 26 of wood, paper,and wood, respectively, may be adhesively united during or after theimpregnating operation so that, when the shank piece members of propersize and shape are cut from these layers, these three lower members willform a unit which may be assembled in the same manner as the fabric andinner paper layers. The remaining top layer 22 of wood can be assembledon the others separately. By this procedure there will be a maximum ofonly three separate members or units to assemble and each unit willcontain at least one layer which corresponds in size and shape to theshank and heel portions of the insole so that the three units can bereadily located with respect to one another.

The stiffening material with which the layers of fibrous material areimpregnated comprises a substance or solution which, as hereinillustrated. is preferably both thermosetting and thermoplastic incharacter but in which the thermoplastic quality predominates. Moreover,as indicated above, the stiffening material is also of an adhesive orbonding nature so that it will act as a bonding or fusing agent as wellas a stiffening medium. One material that has been found to meet theabove requirements comprises a thermm plastic impregnating varnishcontaining a medium quantity of 'thermosetting resin, the mixture beingsuch that when the varnish is applied to fibrous materials, such ascloth, wood or paper and the solvent is removed, the stiffening rialwill, under proper activation, for example, heat and pressure in thepresent case, bond or fuse the layers of fibrous material firmlytogether into a single integral mass or unit which is relatively firmand stiff at room temperature but which can be rendered pliable again atelevated temperature so that the unit can sub-se quently be remolded andconformed to any desired shape under comparatively low pressure. Oneexample of a stiffening material or varnish which be used is thefollowing:

Acetone (solvent) 199g I Part :Vinylite-XYSG (vinyl acetal resin) 150One Step Phenolic Resin 150 Ethyl alcohol .(solvent) 1260 impregnatingthe different layers of fibrous materials Part A and Part B of theformula are mixed in equal volumes. The unsized kraft paper and thefabric layers may be treated by passing them through the mixturefollowed by airdrying and heating at 105 C. for a predetermined period.Figure 5 illustrates a convenient method of impregnating the paper andfabric layers which consists of drawing a layer or strip .43 of eithermaterial around a rotary supporting roll 18 and passing it under a pairof submerging rolls 59,52 rotatably mounted in a tank 5% con tainingstiffening material Tl e strip 55 passes from the tank around anothersupporting roll 58 and is g ided through a horizontal drying chamber 50from whence it may be wound upon a receiving roll (not shown) and thenheated for 20 to minutes at a temperature of 105 C.

While the wood veneer, such as the basswood which forms the outer layersof the shank piece, can be used without impregnating it with stiffeningmaterial because the wood is normally hard and stiff enough to be usedwithout additional stiffening, the wood layer may, if desired, beimpregnated the same as the cloth and paper layers by submerging it inthe stifl'enin' solution for about 15 minutes and then air-drying thewood and heating it at 105 C. for 15 or 20 minutes. Since layers offibrous material treated in the manner amount of lateral displacement orflow when embodied under pressure in articles of laminated formation,the several members forming the shank piece may all be cut to theirproper shapes and sizes at the time they are died out of the variouslayers of impregnated fibrous materials. It should be pointed out,however, that while the wood layers have practically no. displacement orflow under relatively heavy pressure, the inner or paper and fabriclayers do flow sufiiciently under heavy pressure to permit the unit tobe molded to tr e required shape both laterally and longitudinally.

The members which make up the shank piece, including the outer woodlayers if desired, having been impregnated and arranged in assembledrelation, as illustrated in Figs. 1 to 4:, inclusive, the assembly isnext molded under heat and pressure to secure the layers in assembledrelation and to bond or fuse them together into a single, integral shankpiece unit and simultaneously to conform the'unit to approximately theshape of the shank and heel portions of a last bottom, the stiffeningmaterial rendering the unit relatively hard and stiff after the moldingoperation so that it will retain the shape imparted to it by the molds.The molding operation may be performed in any usual or convenient manneras, for example, in a press 62 (Fig. 6) which, as illustrated, isprovided with upper and lower molds 64, 66 having formed respectivelytherein molding surfaces 68 and iii, the molding surface (52 beingshaped to conform approximately to the longitudinal and transversecurvatures of the shank and heel portions. of the bottom of a last ofmedium or average size and shape, and the surface 10 being generallysimilar in shape to the upper surface 68 but having more pronounced orsharper curvatures for accommodating the materials displaced by theupper molding surface described do not have a very great I ag ng;

68. The molds 64, ,66 are .guidedrelatively-to each other in operationby dowels-12 and .eachis provided with a pair of electric heating units14, as illustrated in Fig. 6. The total pressure exerted by the moldsupon the shank piece members to obtain the desired results ;is about ,16 tons or approximately 4000 pounds to thesquare inch and this pressureis maintained for about ten minutes. The molds are heated to about 300F. in order to bond or fuse the layers together into a single, integralunit whilesimultaneously rendering the materials sufliciently pliable topermit the apparatus to mold them to the shape defined by the moldingsurfaces-68 and 10,

After the layers have been united and molded to the desired shape, theheat, may be turned off and the materials permittedto cool sufficientlywhile still under pressure to form a relatively stiff and rigid shankpiece unit 75, such as that illustrated in Fig. '7. As shown in thatfigure the shank piece has an inner surface ,18 which conformsapproximately in shape -to the longitudinal and transverse curvatures ofalast :bottom of average size and shape, and an outersurface which ismore sharply rounded-or curved owing to the thicknesses of the innerlayers of fibrous materials which were interposed between the top layer22 and the bottom layer 26. Moreover, as illustrated in Fig. '7, theshank piece is firm and stiff enough after the molding operation toretain indefinitely the shape impartedto it by the molds.

The present invention contemplates not only the provision of an improvedshank piece composed of fibrous materials, but also the provision, as anew article of manufacture, of an integral shoe bottom unit adaptedwithout additional preparation to be used in a shoe. In carrying outthis aspect of the invention, the molded shank piece 16 is united withan insole 32 (Fig. 9.) to form a complete shoe bottom unit. It isdesirable, however, besides securing the shank piece and insole togetherto form a single shoe bottom unit, to have the unit, including the shankpiece, conform accurately to the shape of the bottom of a particularlast, as for example, the last upon which the shoe is to be built.Accordingly, the hardened shank pi ce 16 is positioned upon the outer orlower surface of the insole 82, which may be readily accomplishedbecause the peripheries or edge contours of the insole and shank piececorrespond accurately to one another. The assembled insole and shankpiece are next mounted on the bottom of a last 84 (Fig. 8) upon whichthe shoe is to be builtv and are pressed against the bottom of the lastunder pressure and heat sufiicient to mold the insole accurately to theshape of the last bottomand to render the shank piec pliable again andto remold it accurately to the shape of the shank and heel portions ofthe last bottom or, in other words, into accurate conformity with therear portion of the molded insole;

The molding of the insole and remolding of the shank piece may beaccomplished in any usual or conventional type of press such, forexample, as a sole attaching press of the general type disclosed inPatent NO. l,9llf.,5 i6, granted March 14, 1933, upon an applicationfiled in the name of George H. Barge. The sole attaching press, asillustrated in the Barge patent, is provided with a flexible bladder orbag 86 carried in a base 88 and filled with liquid, such as water, whichis heated by an electricheating unit through the base nto the bladder.on th st i" pr d against the flexzm 92 pivoted on a pin 9% and arrangedto swung downwardly toward the bladder by a pair of springs 96 which aretensioned manually to apply pressure by suitable mechanism (not shown),the pressure being maintained by a latch arranged to engage notches 93formed in the rear end of the arm 92. The arm 92 carries pressureapplying abutments I00, Hi2 arranged respectively to engage and applypressure to the forward portion of the last and its rear or heelportion.

The pressure desired for molding the insole and remolding the shankpiece to the shape of the last bottom is preferably from 100 to 300pounds to the square inch, which is much less pressure than was utilizedfor initially fusing and molding the several layers to form the shankpiece unit and for conforming the unit approximately to the contour of amedium shaped last bottom. This relatively low pressure, however, issufiicient to mold the insole and to remold the shank piece as describedwith the advantage that it is not great enough to damage the last usedin this final molding operation as the much heavier pressure of theinitial molding operation clearly would be. The heat applied in thissecond molding operation preferably ranges from 250 to 300 F. whichrenders the shank piece pliable and permits it to be readily remoldedinto accurate conformity with the transverse and longitudinal curvaturesof the insole and last bottom. The pressure and heat are maintained onthe insole and shank piece from 10 to minutes. Since the insole andshank piece are to form a single, integral shoe bottom unit, the shankpiece must also be permanently attached to the insole and this may beaccomplished during the molding operation by applying adhesive such aslatex or rubber cement to the opposing surfaces of the insole and shankpiece prior to assembling them on the bottom of the last. If desired, athermosetting adhesive such as neoprene may be used for this purposeinstead of the adhesives mentioned above. After the unit has been moldedand conformed, the heat is turned off and the unit is permitted to 0001under the full pressure to eliminate any strains set up in the moldingoperation so that the unit will retain its shape permanently unlessremolded.

Although the operation of molding the insole and shank piece into anintegral shoe bottom unit is disclosed herein by way of example as beingperformed in a sole attaching press of the type disclosed in the Bargepatent, this operation can obviously be carried out with other types ofpresses adapted to apply heat and pressure to the bottom of a last orshoe. Moreover, it is not essential that the molding press be adapted toapply heat to the last or shoe parts since the shank piece may, ifdesired, be heated to the required temperature separately in an oven orother heating device and the positioned on the cementcoated outersurface of the insol and assembled with the insole on the last bottom,the assembly being then mounted, for example, in a sole attaching pressarranged to apply pressure to the last bottom. A press which is welladapted for use in molding the shoe bottom unit after the shank piecehas been heated separately, as described above, is a press or pad box ofthe general type disclosed in Letters Patent of the United States No.2,047,185, granted July 14, 1936, on an application filed in the name ofMilton H. Ballard et al.

Although it is not essential to carrying out the method, the cooling ofthe shoe bottom unit While under pressure may be accelerated bycirculating cold water around or through the pad or bladder, therebyspeeding up this operation and reducing the time and expense ofproducing the units in quantity or on a production basis.

Fig. 9 illustrates the completed shoe bottom unit I84 consisting of themolded insole 82, conforming accurately in shape to the bottom contouror curvature of the last 84, and the laminated shank piece 16permanently attached by adhesive to the outer face of the insole, theshank piece having been remolded to conform accurately in shape to theshank and heel portions of the in- .sole and last bottom. Fig. 10illustrates the transverse curvatures which are imparted to the insoleand shank piece at an intermediate portion of the unit or at a pointlocated forwardly of the heel breast line in a finished shoe.

It will be observed in Figs. 9 and 10 that the longitudinal andtransverse curvatures of the rear portion of the shoe bottom unit I04are somewhat greater or more sharply rounded than th correspondingcurvatures of the shank piece illustrated in Fig. 7 because of theconformation of the unit to a particular last bottom. These greatercurvatures of the completed bottom unit will be retained permanently inthe finished article because of th character of the materials making upthe shank piece and also because of the nature of the stiffeningmaterial with which the materials of the shank piece were impregnated.However, if it should be desired to change the shape of the shoe bottomunit after it has been completed, this can be done, as indicated above,by merely activating the stiffening material by applying heat to theshank piece to render it pliable again and then remolding the shoebottom unit to the shape desired. It should be noted that, since theshank piece is coextensive in outline with the shank and heel portionsof the insole, the unit as a whole will support the foot Widthwise ortransversely as well as longitudinally.

Although the shoe bottom unit of Figs. 9 and 10 is stiff and rigidenough to support the foot, including its shank and heel portions, inproper position both longitudinally and transversely during the wearingof the shoe, it nevertheless has sufilcient resiliency to permit it toyield or flex slightly at the shank under relatively heavy pressure. Forall practical purposes, however, the shank and heel portions of the unitcomprise a substantially rigid, non-yielding arch or bridge whichprovides a firm, positive support for the rear portion of the foot bothlaterally and longitudinally, thereby increasing the comfort of thewearer and tending to produce a tread in walking which is substantiallyeven or uniform which, in turn, reduces the tendency to wear out theheel or the top lift of the shoe unevenly or prematurely, and alsominimizes the chances of distorting or running over the counter or backpart of the shoe or breaking the heel breast flap, which often occurs insuch cases.

Although the shank piece member of the shoe bottom unit is extremelystiff and hard after being fused and molded into the unitary member, itis not so hard or rigid that it will prevent or interfere with the usualshoemaking operations such, for example, as lasting the upper orattaching a heel to the shoe. An upper may, therefore, be worked overthe shoe bottom unit and secured in lasted relation thereto by tacks orstaples in the usual manner. As pointed out above, the material formingthe outer layers of the shank piece, namely, the wood, is of a characterwhich offers less resistance to penetration than the materials formingthe inner layers, particularly when the latter are compressed or moldedand, accordingly, the tacks, staples or other fastenings will readilyenter the shank piece when driven without being bent or deflected fromthe line of drive. It is preferable, however, in lasting the upper, toperform this operation with tacks or staples which do not extendcompletely through the shoe bottom unit at its shank and heel portionsand which will not have to be clinched against the inner surface of theunit or insole. In other words, the composition or density of the shankpiece is such that, while fastenings such as nails, tacks or staples canbe readily driven into or through the shank piece, the latter will holdthe fastenings firmly without being clinched and accordingly short tacksand staples may be used, if desired, in place of longer lasting tacksadapted to be clinched or curved staples ordinarily used for lasting theforepart and side portions of the upper. It should be pointed out,however, that long lasting tacks or curved staples may be used ifpreferred.

The relatively great holding power of the fastenings in the present shoebottom unit will tend to prevent the upper from creeping or becomingdisplaced lengthwise at the shank portion of the shoe and the firmnessor rigidity of the shank piece will also provide a better anchorage thanusual for the heel attaching nails and consequently will contributetoward a stronger attachment of the heel to the shoe bottom. Moreover,since the shank piece is coextensive with the periphery of the insole atthe heel seat portion of the shoe, the heel attaching nails will passthrough the shank piece as well as through the insole and will thussecure or look the heel, the counter stiffener, and the insole includingthe shank piece, into one firm, rigid assembly which is much strongerthan the usual construction in which the heel is attached only to therelatively flimsy insole at the heel seat.

The shoe bottom unit of the present invention, therefore, provides afirm, rigid support for the foot which supports the rear portion thereoflaterally and longitudinally, and it also provides a stronger or firmerbase than usual for receiving and holding lasting tacks and staples.Since the shank piece extends over the entire heel seat portion of theshoe bottom, the heel attaching nails will pass through it therebylocking the heel, counter and bottom unit together as a solid unit whichresults in a much stronger attachment of the heel to the shoe and alsoprovides additional support for the rear portion of the upper. By reasonof the above features and characteristics of the shoe bottom unit, theshoe is rendered more comfortable to the wearer and tends to cause thewearer to tread more evenly or uniformly in walking which, as stated,prevents the heel from being run over, the breast fiap from breaking,and the counter or back part of the shoe from being distorted or bulgedout of shape.

Having thus described our invention, what we claim as new and desire tosecure by Letters Patent of the United States is:

1. As a new article of manufacture, a shank piece of laminated formationconsisting of a plurality of layers of fibrous material secured togetherby hardened stiffening material of an adhesive nature, said layerscomprising outer layers of relatively stiff material and inner layers ofrelatively flexible material.

2. As a new article of manufacture, a shank piece of laminated formationcomprising a plurality of layers of fibrous material secured together bya hardened reinforcing substance of an adhesive nature, the material ofthe outer layers of said shank piece being of a character offering lessresistance to penetration by lasting fastenings or the like than thematerial of the inner layers of said shank piece.

3. As a new article of manufacture, a shank piece of laminated formationconsisting of a plurality of layers of fibrous material impregnatedwith, and secured in assembled relation by, hardened stiffening materialof an adhesive nature, said layers comprising outer layers of Wood andinner layers of fibrous composition material.

4. As a new article of manufacture, a shank piece of laminated formationconsisting of a plurality of superimposed layers of fibrous materialimpregnated with stiffening material of a bonding nature which stiifenssaid layers and secures them together in assembled relation to eachother, said layers comprising outer layers of relatively hard, stifffibrous material and inner layers of fibrous materials of differentdegrees of hardness and flexibility.

5. As a new article of manufacture, a shank piece of laminated formationconsisting of a plurality of layers of fibrous material impregnatedwith, and secured together by, hardened stiffening material of athermoplastic nature, said layers comprising top and bottom layers ofequal hardness and rigidity, an inner layer of the same hardness andrigidity as the top and bottom layers, and additional inner layers whichare normally softer and more flexible than said top and bottom layers.

6. As a new article of manufacture, a shank piece of laminated formationconsisting of a plurality of layers of fibrous material secured togetherby hardened stiffening material of an adhesive nature, said layerscomprising outer layers of relatively stiff material and inner layers ofrelatively flexible material, said inner layers being impregnated withsaid stiffening material to render them relatively hard and stiff, andsaid outer layers being unimpregnated With stiffening material and beingless resistant to penetration by driven fastening members than saidinner layers.

'7. As a new article of manufacture, a shank iece of laminated formationconsisting of outer layers of Wood, and a plurality of inner layerscomposed respectively of wood, paper and fabric material.

8. As a new article of manufacture, a shank piece of laminated formationconsisting of a plurality of layers of fibrous material impregnatedwith, and secured in assembled relation by, hardened stiffening materialof an adhesive nature, said layers comprising top and bottom layers ofwood, and intermediate layers composed respectively of paper, wood andfabric material.

9. As a new article of manufacture, a shank piece of laminated formationcomprising a plurality of layers of fibrous material united into asingle unit, said layers consisting of top and bottom layers of wood andinner layers comprising, respectively, a layer of fabric material belowthe top wood layer, a plurality of layers 'of paper below said fabriclayer, a layer of wood below said paper layers, and a layer of paperbetween the last-named wood layer and the bottom wood layer.

10. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialsecured togather in assembled relation by hardened stiffening materialof an adhesive nature, said layers comprising outer layers composed ofwood and inner layers composed respectively of wood, paper and fabricmaterial, said inner layers being impregnated with said stiffeningmaterial to render them relatively hard and stiff, and said outer woodlayers being unimpregnated with stiffening material and ofiering lessresistance to penetration than said inner layers.

11. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of superimposed layers of fibrousmaterial secured together by hardened stiffening material of an adhesivenature before hardening, said layers comprising top and bottom layers ofwood, a layer of fabric material and a layer of paper next to said topand bottom layers respectively, a layer of wood next to said layer ofpaper, and a plurality of layers of paper between the last-named woodlayer and the layer of fabric material.

12. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured in assembled relation by, hardenedstiffening material of an adhesive nature, said layers comprising outerlayers of equal size and shape and inner layers which diminish graduallyin size.

13. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of superimposed layers of fibrous material impregnated with, and secured together in assembled relation by,hardened stiffening material of an adhesive nature, said layerscomprising top and bottom layers of equal size and shape, and innerlayers which gradually diminish in size progressively from an upperinner layer to a lower inner layer.

14. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured in assembled relation by, hardenedstiffening material of a bonding nature, said layers comprising outerlayers of equal size and shape composed of relatively stiff, rigidmaterial and inner layers composed of relatively flexible material, saidinner layers diminishing gradually in size from that of said outerlayers from an upper inner layer to a lower inner layer.

15. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured in assembled relation by, hardenedstiffening material of an adhesive nature, said layers comprising topand bottom layers of equal size and shape composed of wood, said layerscorresponding in shape to the shank and heel portions of an insole, andinner layers comprising, respectively, a layer of fabric below said topwood layer and equal in size and shape thereto, a plurality of layers ofpaper below said fabric layer, said paper layers diminishing graduallyin size from the top to the lowermost layer thereof, a layer of woodbelow said paper layers and equal in size and shape to said top andbottom layers, and another layer of paper between the last-named woodlayer and the bottom wood layer and equal in size and shape to saidbottom wood layer.

16. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured together in assembled relation by,hardened thermoplastic impregnating varnish, said layers includinglayers of wood and layers of fibrous material more flexible than woodbut also more resistant than wood to penetration by driven fastenings.

17. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured in assembled relation by, hardenedstiffening material of an adhesive nature, said layers comprising outerlayers of basswood, and inner layers composed respectively of cloth,basswood and unsized kraft paper, said stiffening material consisting ofa thermoplastic impregnating varnish. I

18. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of united layers of fibrousmaterial, said layers comprising outer layers of wood and inner layerscomposed respectively of wood, paper and fabric material, said shankpiece corresponding in outline to the shank and heel portions of aninsole, and conforming approximately in shape to the bottom of a last.

19. As a new article of manufacture, a unitary shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured together in assembled relation by,hardened stiffening material of an adhesive nature, said shank piececorresponding in outline to the edgecontour of the rear portion of aninsole and conforming approximately in shape to the curvatures of a lastbottom, said layers comprising outer layers of relatively stiff, rigidmaterial and inner layers of relatively flexible material.

20. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured together in assembled relation by,hardened stifiening material of an adhesive nature, said layerscomprising outer layers of relatively stiff, rigid material and innerlayers of relatively flexible material, said outer layers correspondingin size and shapeto the shank and heel portions of an insole, and saidinner layers diminishing gradually in size from said outer layers froman upper inner layer to a lower inner layer.

21. As a new article of manufacture, a unitary shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured in assembled relation by, hardenedstiffening material of an adhesive nature, said layers comprising outerlayers of relatively hard, stiff material and inner layers of relativelyyielding, flexible material, said outer layers corresponding in outlineto the edge contour of the shank and heel portions of an insole andconforming approximately in shape to the longitudinal and transversecurv atures of a last bottom, and said inner layers diminishingprogressively in size from the size of said outer layers from an upperinner layer to a lower inner layer.

22. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of superimposed layers of fibrousmaterial impregnated with and hardened by stiffen- 'ing material of anadhesive nature which fuses the layers together in assembled relation toeach other, said layers comprising outer layers of relatively stiffmaterial and inner layers of relatively flexible material, said shankpiece corresponding in outline to the shank and heel portions of aninsole and having its inner surface conforming approximately in shape tothe curvatures of the shank and heel portions of a last bottom, theouter surface of said shank piece corresponding generally to the shapeof said inner surface but having greater curvature imparted thereto bysaid inner layers.

23. As a new article of manufacture, a shank piece of laminatedformation consisting of a plurality of layers of fibrous materialimpregnated with, and secured in assembled relation by, hardenedstiffening material of an adhesive nature, said layers comprising topand bottom layers of equal size composed of wood, and inner layerscomposed respectively of wood and composition fibrous material, saidinner layers diminiehing progressively in size from an upper inner layerto a lower inner layer, and said top and bottom layers corresponding inoutline to the shank and heel portions of an insole with said top layerconforming approximately in shape to the shank and heel portions of alast bottom and said bottom layer conforming generally in shape to saidtop layer but being of greater curvature by reason of the diminishinginner layers between said top and bottom layers.

24. As a new article of manufacture, a shoe bottom unit comprising aninsole, and a shank piece of laminated formation secured to said insoleand reinforcing the shank and heel portions thereof, said shank piececonsisting of a plurality of layers of fibrous material impregnatedwith, and secured in assembled relation by, hardened stiffening materialof an adhesive nature, the inner surface of said unit conformingaccurately in shape to the bottom surface of a last, and the outersurface of said unit corresponding generally to the shape of said innersurface but having greater curvature by reason of the layers of saidshank piece.

25. As a new article of manufacture, a shoe bottom unit comprising aninsole, and a shank piece of laminated formation adhesively secured tothe outer surface of said insole and reinforcing the shank and heelportions thereof, said shank piece consisting of a plurality of layersof fibrous material impregnated with, and secured together in assembledrelation by, hardened stiffening material of an adhesive nature, saidlayers comprising outer layers of relatively stifi, rigid material andinner layers of relatively flexible material, the inner surface of saidunit being complemenial in. shape to the bottom surface of a last.

26. As a new article of manufacture, a shoe bottom unit comprising aninsole, and a shank piece of laminated formation secured to the insoleby cement and reinforcing the shank and heel portions thereof, saidshank piece consisting of a plurality of layers of fibrous materiail theouter layers of which are composed of wood and the inner layers of whichare composed respectively of wood, paper, and fabric material, saidlayers being hardened and secured together in assem- I bled relation bystiffening material of an'adhesive nature.

27. As a new article of manufacture, a shoe bottom unit comprising aninsole, and a shank piece of laminated formation adhesively secured tothe outer surface of the insole and reinforcing the shank and heelportions thereof, said shank piece consisting of a plurality of layersof fibrous material impregnated with, and secured together in assembledrelation by, hardened stiffening material of an adhesive nature, saidlayers comprising outer layers of wood and inner layers of wood, paper,and fabric material respectively, said outer layers corresponding inoutline to the shank and heel portions of the insole and said innerlayers diminishing in size from that of said outer layers from an upperinner layer to a lower inner layer, and the inner surface of said unitconforming accurately in shape to the bottom surface of a last.

28. As a new article of manufacture, a shoe bottom unit comprising aninsole, and a shank piece of laminated formation secured by adhesive tothe outer surface of said insole and reinforcing the shank and heelportions thereof, said shank piece consisting of a plurality of layersof fibrous material impregnated with, and secured together in assembledrelation by, hardened stiffening material of an adhesive nature, saidlayers comprising top and bottom layers corresponding in outline to theedge contour of the insole, and inner layers which diminish gradually insize from an upper inner layer to a lower inner layer, the inner surfaceof said unit being complemental in shape to the bottom surface of alast, and the outer surface of the unit conforming generally in shape toits inner surface but being more sharply curved laterally andlongitudinally by reason of the inner layers of said shank piece.

29. As a new article of manufacture, a shoe bottom unit comprising aninsole, and a shank piece of laminated formation secured by cement tothe outer surface of the insole and reinforcing the shank and heelportions thereof, said shank piece consisting of a plurality ofsuperimposed layers of fibrous material impregnated and hardened with,and secured in assembled relation by, stiffening material comprising athermoplastic impregnating varnish, said layers comprising top andbottom layers of equal size and shape composed of wood, and inner layerscomposed respectively of wood, paper, and fabric material, said innerlayers diminishing gradually in size from an upper to a lower innerlayer, the inner surface of said bottom unit conforming accurately inshape to the bottom surface of a last, and the outer surface of saidunit including the shank piece corresponding generally to the shape ofsaid inner surface but being more sharply curved by reason of the innerlayers of said shank piece.

30. That improvement in methods of making bottom units for shoes whichconsists in providing a shank piece of relatively stiff, rigid fibrousmaterial which corresponds in outline to the shank and heel portions ofan insole and has been molded to conform approximately in shape to thebottom of a last, the material of said shank piece being of a naturewhich permits it to be rendered pliable again, securing the shank pieceto an insole on the bottom of a last, and molding the insole intoaccurate conformity with the shape of the last bottom whilesimultaneously rendering the shank piece pliable and remolding it intoconformity with said last bottom.

31. That improvement in methods of making bottom units for shoes whichconsists in molding.

a shank piece of relatively stiff fibrous material to conform itapproximately to the shape of the bottom of a last. assembling the shankpiece with an insole on a last bottom with adhesive between the insoleand shank piece, and applying heat and pressure to the insole and shankpiece to unite them adhesively and to mold the insole to the shape ofthe last bottom, and simultaneously to remold the shank piece accuratelyto the shape of the insole and last bottom.

32. That improvement in methods of making bottom units for shoes whichconsists in providing a shank piece of relatively stiff, rigid materialwhich corresponds in outline to the shank and heel portions of an insoleand has been molded to conform approximately in shape to the bottom of alast, assembling the shank piece with an insole on a last bottom, andmolding the insole and remolding the shank piece accurately to the shapeof the last bottom while simultaneously attaching the shank piece to theinsole.

33. That improvement in methods of making bottom units for shoes whichconsists in providing a shank piece of fibrous material which has beenmolded to conform approximately in shape to the bottom of a last and hasbeen impregnated with stiffening material to render it relatively stiffand rigid, assembling said shank piece with an insole on the bottom of alast with adhesive between the insole and shank piece, and applying heatand pressure to the assembled members to mold the insole to the shape ofthe last bottom and to remold the shank piece to said shape whilesimultaneously attaching the shank piece adhesively to the insole.

34. That improvement in methods of making bottom members for shoes whichconsists in providing a shank piece of fibrous material which iscoextensive in edge contour with the shank and heel portions of aninsole and has been molded to conform approximately in shape to thebottom of a last, said shank piece being impregnated with stiffeningmaterial of a thermoplastic nature to render it relatively hard andstifi, assembling ie shank piece with an insole on the bottom of a last,and applying heat and pressure to the insole and shank piece to mold theinsole to the shape of the last bottom and to render the shank piecepliable and to remold it accurately to the shape of the insole and lastbottom.

35. That improvement in methods of making bottom units for shoes whichconsists in providing a shank piece of laminated formation consisting ofa plurality of layers of fibrous material impregnated with, and securedtogether by, hardened stiffening material of an adhesive nature, saidshank piece being molded to conform approximately in shape to the bottomof a last, 1

assembling the shank piece with an insole on the bottom of a last,applying heat and pressure to the assembled members to mold the insoleinto conformity with the last bottom and to remold the shank pieceaccurately to the shape of the insole and last bottom, and cementattaching the shank piece to the insole.

36. That improvement in methods of making bottom units for shoes whichconsists in providng a shank piece of fibrous material molded to conformapproximately in shape to the bottom of a last and impregnated withstiffening material of a thermoplastic nature to render it relativelyhard and stiff, assembling the shank piece with an insole on the bottomof a last with cement between the insole and the shank piece, applyingand pressure to the assembled members to mold the insole to the shape ofthe last bottom, to render the shank piece pliable and remold itaccurately to the shape of the insole and last bottom, and also to causethe shank piece to become attached to the insole by the cementtherebetween, and shutting off the heat but maintaining the pressureupon said members until they have cooled sufliciently to cause the shankpiece to harden so that it will retain its shape permanently.

37. That improvement in methods of making bottom units for shoes whichconsists in providing a shank piece of laminated formation consisting offibrous materials molded to conform approximately in shape to the bottomof a last and impregnated with hardened stiffening material of athermoplastic nature to render it relatively stiff and rigid, applyingheat to said shank piece to render it relatively pliable, assembling theshank piece with an insole on the bottom of a last with cement betweenthe insole and shank piece, applying pressure to the assembled membersto mold the insole to the shape of the last bottom and to remold thepliable shank piece to the shape 01 the insole and last bottom, saidpressure also causing the shank piece to become cement attached to theinsole, and maintaining the pressure until the shank piece has cooledsufficiently to harden again so that it will retain its remolded shapepermanently at normal temperature.

38. That improvement in methods of making shoe bottom units whichconsists in providing a shank piece of fibrous material of laminatedformation which corresponds in outline to the shank and heel portions ofan insole and is impregnated with a thermoplastic stiffening material torender it relatively stifi and rigid, molding the shank piece betweenmembers arranged to apply heat and pressure to render the fibrousmaterial pliable and to mold it to approximately the shape of the bottomof a last, permitting the shank piece to stiffen again and positioningit on the outer surface of an insole with cement between the insole andshank piece, mounting the insole and shank piece on the bottom of alast, and applying heat and pressure to the insole and shank piece tomold the insole to the shape of the last bottom and to render the shankpiece pliable again and to remold it accurately to the shape of theinsole and last bottom, and simultaneously to attach the shank pieceadhesively to the outer surface of the insole.

'39. That improvement in methods of making shoe bottom members whichconsists in providing a plurality of layers of fibrous material some ofwhich correspond in outline to the shank and heel portions of an insole,said layers being impreg'nated and hardened with stiifening material ofa thermoplastic nature, assembling said layers in superimposed relationand molding them under heat and pressure to render them pliable and tofuse them together into a unitary shank piece and simultaneously toconform said shank piece to approximately the shape of the shank andheel portions of a last bottom, assembling the shank piece with aninsole on a form, and pressing the insole and shank piece and the formtogether under heat to mold the insole to the shape 'of the form and torender the shank piece pliable again and to remold it accurately to theshape of said form.

40. That improvement in methods of making shank pieces which consists inimpregnating a plurality of layers of different fibrous materials withstiffening material of an adhesive nature to render the fibrousmaterials relatively stifi and rigid, cutting from said layers memberswhich vary in size and shape and the largest members of which correspondin outline to the shank and heel portions of an insole, arranging saidmembers in assembled relation with the largest members forming the outerlayers of the assembly, and molding the assembled members to secure themin said assembled relation and to conform them to approximately theshape of the bottom of a last. v

41. That improvement in methods of making shank pieces which consists inimpregnating layers of relatively stiff fibrous material and layers ofrelatively flexible fibrous material with stiffening material of anadhesive nature, cutting from said' layers members which correspond insize and shape to the shank and heel portions of an insole and othermembers which diminish in size from said first-named members to muchsmaller members, assembling said members in superimposed relation withthe members of stiff, fibrous material forming the outer layers of theassembly and the members of relatively flexible material, including thediminishing members, forming the inner layers of said assembly, andmolding the assembled members under heat and pressure to fuse themtogether into a unitary shank piece of laminated formation andsimultaneously to conform the shank piece to approximately the shape ofthe shank and heel portions of a last bottom.

42. That improvement in methods of makin shank pieces for shoes whichconsists in impregnating a layer of paper and a layer of fabric materialwith stiffening material of an adhesive nature, thereby rendering saidlayers relatively stiff and rigid, cutting from said layers memberswhich correspond in size and shape to the shank and heel portions of aninsole and other members which diminish gradually in size from saidfirst-named members to much smaller members, cutting from a layer ofwood a plurality of members which correspond in size and shape to theshank and heel portions of an insole, arranging the wood, fabric, andpaper members in assembled relation with wood members forming the topand bottom layers of the assembly and with wood, fabric, and papermembers, including the diminishing members, forming the inner layers ofsaid assembly, and molding the assembled members under heat and pressureto render the stiffened members pliable and to unite them adhesivelyinto an integral shank piece of laminated formation, and simultaneouslyto conform said shank piece to approximately the shape of the shank andheel portions of a last bottom.

43. That improvement in methods of making shank pieces which consists inimpregnating a layer of paper and a layer of fabric material with aplastic stiffening material of an adhesive nature to render themrelatively stiff and rigid, cutting from said layers members whichcorrespond in size and shape to the shank and heel portions of aninsole, cutting from the paper layer further members which diminishgradually in size from the first-named members to much smaller members,providing a layer of wood unimpregnated with stiffening material and ofa character which offers less resistance to penetration than the paperand fabric layers, cutting from the wood layer a plurality of membersequal in size and shape to said first-named members of paper and fabricmaterial. assemblin said members in superimposed relation with theunimpre nated wood members forming the outer layers of the assembly andthe other members of wood,

paper, and fabric forming the inner layers thereof, activating theplastic stiifening material to render said inner layers pliable, andmolding the assembled members to secure them together into a unitaryshank piece of laminated formation and to conform said shank piece toapproximate ly the shape of the bottom of a last.

44. That improvement in methods of making shank pieces for shoes whichconsists in impregnating a plurality of layers of fibrous material withstiffening material of a thermoplastic nature to render said layersrelatively stiff, said layers being composed respectively of wood,fabric material, and unsized paper, cutting from said layers memberswhich correspond in size and shape to the shank and heel portions of aninsole and from the paper layer only cutting additional members whichdiminish gradually in size from that of said first-named members to muchsmaller members, assembling said members in superimposed relation withthe wood members forming the top and bottom layers of the assembly andwith a fabric member and a paper member located next to said top andbottom layers, respectively, with a wood member located next to saidpaper member, and with the diminishing paper members interposed betweenthe last-named wood member and the fabric member, said paper membersbeing arranged so that they diminish progressively in size from the topto the lowest member thereof, and subjecting the assembled members torelatively great heat and pressure between molds adapted to conform theassembly to approximately the shape of the shank and heel portions of alast bottom and to fuse the members together by reason of saidstiffening material, thereby producing a unitary shank piece oflaminated formation composed of fibrous material and conformingapproximately in shape to the shank and heel portions of a last bottom.

45. That improvement in methods of making shank pieces for use in shoeswhich consists in impregnating a plurality of layers of fibrous materialwith plastic stiffening material of an adhesive nature to render saidlayers relatively stiff and rigid, cutting from said layers memberswhich correspond in size and shape to the shank and heel portions of aninsole and other members which diminish gradually from said size to muchsmaller members, assembling said members in superimposed relation withthe first-named members forming the outer layers of the assembly,activating the plastic stiffening material to render said memberspliable, molding said members to unite them into a unitary shank pieceof laminated formation and to conform said shank piece to approximatelythe shape of the bottom of a last, activating the stiffening material inthe unitary shank piece unit to render it pliable again, and remoldingsaid shank piece into ac curate conformity with the shank and heelportions of a last bottom.

45. That improvement in methods of making shank pieces for use in shoeswhich consists in impregnating a plurality of layers of fibrous materialwith thermoplastic stiifening material of an adhesive nature to renderthe materials relatively hard and stiff, cutting from said layersmembers which correspond in size and shape to the shank and heelportions of an insole and other members which diminish gradually in sizefrom said first-named members to relatively small members, arrangingsaid members in assembled relation with the first-named members formingthe top and bottom layers of the assembly, molding the assembled membersunder substantial heat and pressure to render them pliable and to fusethem together into an integral shank piece of laminated formation andsimultaneously to conform the shank piece to approximately the shape ofthe shank and. heel portions of a last bottom, and thereafter remoldingthe shank piece under less heat and pressure to render it pliable againand then to conform it accurately to the shape of the shank and heelportions of a particular last bottom.

THOMAS C. MORRIS. FRANK S. GREGORY, JR.

